2ZR-FXE (FUEL): FUEL PUMP (w/ Canister Pump Module): REMOVAL; 2021 - 2022 MY Corolla Corolla HV [04/2020

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000002DPVE
Model Year Start: 2021	Model: Corolla	Prod Date Range: [04/2020 - 09/2022]
Title: 2ZR-FXE (FUEL): FUEL PUMP (w/ Canister Pump Module): REMOVAL; 2021 - 2022 MY Corolla Corolla HV [04/2020 - 09/2022]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel pump removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Control System (for HV Model)
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Pre-collision System (for HV Model)
Replacement of fuel pump	Inspection after repair	Poor idle, etc. Engine start function, etc.

CAUTION:

Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.

Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

NOTICE:

After the ignition switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System (for HV Model))

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here

3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

4. REMOVE REAR SEAT ASSEMBLY

Click here

5. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Disconnect the 2 rear seat inner with center belt assembly LH connectors.

(b) Disengage the clamp.

(d) Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

*a	Protective Tape

(e) Disconnect the fuel suction tube with pump and gauge assembly connector and fuel tank pressure sensor (vapor pressure sensor) connector.

6. REMOVE FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR)

Click here

7. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Disconnect the fuel tank vent hose sub-assembly from the fuel suction tube with pump and gauge assembly.

Click here

8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) for 2WD:

Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

*1	Fuel Suction Plate Sub-assembly
*2	Tube Joint Clip
*3	Fuel Tank Main Tube Sub-assembly
*a	Fuel Tube Joint
*b	O-ring
*c	Nylon Tube
	Pull off
	Pull off

NOTICE:

Remove any foreign matter on the fuel tube joint before performing this work.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Be sure to disconnect the fuel tube joint by hand.
Do not bend, twist, pinch or kink the nylon tube.
Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

(b) for 4WD:

*1	Fuel Suction Plate Sub-assembly
*2	Tube Joint Clip
*3	Fuel Tank Main Tube Sub-assembly
*a	Fuel Tube Joint
*b	O-ring
*c	Nylon Tube
	Pull off
	Pull off

Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

NOTICE:

Remove any foreign matter on the fuel tube joint before performing this work.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Be sure to disconnect the fuel tube joint by hand.
Do not bend, twist, pinch or kink the nylon tube.
Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

9. REMOVE FUEL GAUGE WIRE (for 4WD)

(a) Disengage the claw and remove the fuel gauge wire from the fuel pump gauge retainer.

10. REMOVE FUEL PUMP GAUGE RETAINER

(a) Disengage the claw to remove the No. 1 fuel tube clamp.

(b) Remove the fuel pump gauge retainer.

(1) Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

SST: 09808-01071

SST: 09808-14031

09808-01030

09808-01090

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.

*a	Insertion Point
*b	SST (Plate)
*c	SST (Claw)
*d	SST (Bolt)

(2) While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).

(3) Install SST (handle) and an extension bar to SST (plate).

SST: 09808-14031

09808-01010

*a	SST (Handle)
*b	SST (Plate)
*c	SST (Claw)
*d	SST (Bolt)
*e	Extension Bar

(4) Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing down on SST, rotate SST (handle) slowly to loosen the fuel pump gauge retainer.

NOTICE:

Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.
Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.
Do not spin SST too fast or use an impact wrench as this may result in damage to components.
If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

(5) While pressing down on the fuel suction tube with pump and gauge assembly, remove the fuel pump gauge retainer.

11. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

(a) Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge assembly.

(b) Remove the fuel suction tube set gasket from the fuel tank assembly.